JP7354843B2 - Method for manufacturing a molded structure and molded structure - Google Patents

Description

The present invention relates to a method for manufacturing a molded structure and a molded structure.

BACKGROUND ART Conventionally, molded structures are known in which a resin molded body is integrally formed with a base material containing fibers and a thermoplastic resin. Patent Document 1 below discloses that after a base material is press-molded using a pair of molds, molten resin is injected onto the base material through a molding space provided in the molds (a space surrounded by the base material and the mold). A manufacturing method is described in which a resin molded article is formed by doing the following. The molten resin injected onto the base material mixes with the thermoplastic resin constituting the base material. As a result, the resin molded body is joined to the base material.

Patent No. 5186883

However, in the method for manufacturing a molded structure disclosed in Patent Document 1, when the thermoplastic resin (molten resin) flows through the molding space, air or gas generated from the thermoplastic resin (hereinafter referred to as The thermoplastic resin may not flow properly to the end due to the accumulation of various gases (referred to as various gases). In this case, a molded structure including a resin molded body having a desired shape may not be obtained, and the rigidity of the molded structure may be reduced.

The present invention was completed based on the above circumstances, and one of the objects is to provide a molded structure with improved rigidity. Another object of the present invention is to provide a molded structure having a desired shape.

The present invention is a method for manufacturing a molded structure, which includes a pressing step of pressing a fiber resin body composed of at least fibers and a thermoplastic resin with a molding surface of a mold to produce a plate-shaped base material; Injection to produce a resin molded part bonded to the base material by injecting at least a thermoplastic resin into a concave recess provided in the mold while pressing the base material with a molding surface of the mold. The recess includes an inflow recess into which the injected thermoplastic resin flows, and an end recess which is an end portion in the flow direction of the thermoplastic resin flowing from the inflow recess side. In the pressing step, the density of the portion of the base material pressed by the molding surface located around the end recess is equal to or lower than the density of the portion pressed by the molding surface located around the inflow recess. It is characterized in that the fiber resin body is pressed under conditions lower than .

According to the manufacturing method of such a molded structure, in the pressing step, the density of the part of the base material pressed by the molding surface located around the end recess of the mold (referred to as the low density part) is Since the density is set to be lower than the density of the part pressed by the molding surface located around the inflow recess (referred to as the high density part), when thermoplastic resin is injected into the recess in the injection process, the low density Various gases can pass through the recess, and the thermoplastic resin can fill up to the end recess of the recess. Then, it is possible to obtain a highly rigid molded structure in which a resin molded portion having a desired shape is bonded to the base material.

Further, in the pressing step, in the base material, the thickness of the portion pressed by the molding surface located around the end recess is the thickness of the portion pressed by the molding surface located around the inflow recess. The fibrous resin body may be pressed so that it becomes thicker than the fibrous resin body. According to such a method of manufacturing a molded structure, it is possible to easily manufacture a highly rigid molded structure in which a resin molded part of a desired shape is joined to a base material having a low density part and a high density part.

In addition, in the pressing step, the density of the base material decreases as it goes from the side of the part pressed by the molding surface located around the inflow recess to the side of the part pressed by the molding surface located around the end recess. The fiber resin body may be pressed under conditions that gradually become lower. According to such a manufacturing method of a molded structure, when thermoplastic resin is injected into the recess in the injection process, various gases can gradually pass through the base material toward the end recess, and the end The thermoplastic resin can suitably fill up to the recess.

Further, in the pressing step, the end portion of the fiber resin body may be pressed by a molding surface located around the inflow recess. According to such a method of manufacturing a molded structure, a highly rigid molded structure in which the end portion of the base material is reinforced by the resin molded part can be manufactured.

The present invention also provides a molded structure, comprising: a plate-shaped base material made of at least fibers and a thermoplastic resin; a resin molded part made of at least a thermoplastic resin and joined to the base material; The resin molded part includes a main body part, and an extending part connected to the main body part and extending in a direction away from the main body part, and the extending part is provided on the main body side. and a distal end disposed in a direction farther away from the main body than the proximal end; the base material includes a high-density portion joined to the proximal end; The molded structure is characterized in that it includes a low-density portion whose tip portions are joined and whose density is lower than the high-density portion. According to such a molded structure, it is possible to provide a highly rigid molded structure in which resin molded parts are joined from the high density part to the low density part in the base material.

Further, in the above configuration, the main body portion may be disposed at an end portion of the base material. According to such a molded structure, it is possible to provide a highly rigid molded structure in which the end portion of the base material is reinforced by the resin molded part.

According to the present invention, it is possible to provide a molded structure with improved rigidity. Moreover, it becomes possible to provide a molded structure having a desired shape.

A perspective view of a pillar garnish according to an embodiment viewed from inside the vehicle interior. Perspective view of the pillar garnish viewed from outside the vehicle interior An enlarged perspective view of the rib and its surroundings Cross-sectional view of the rib and its surroundings (IV-IV line cross section in Figure 3) Cross-sectional view of the rib and its surroundings (cross-section taken along line V-V in Figure 4) Cross-sectional view showing the mold in the open state Cross-sectional view showing the mold in a closed state Cross-sectional view showing the mold in a closed state (cross section taken along line VIII-VIII in Figure 7) Cross-sectional view showing the mold in a closed state (cross-section taken along line IX-IX in Figure 7) Cross-sectional view showing the state in which thermoplastic resin is injected into the concave part of the mold

<Embodiment>
Embodiments of the present invention will be described with reference to FIGS. 1 to 10. In this embodiment, a pillar garnish (molded structure) 1 that is attached to a columnar center pillar (B pillar) that supports a ceiling from below in an automobile (vehicle) as a vehicle will be described. Each figure will be described with the arrow direction FR as the front, the arrow direction RR as the rear, the arrow direction UP as the upper side, the arrow direction DW as the lower side, the arrow direction IN as the inside of the vehicle interior, and the arrow direction OUT as the outside of the vehicle interior.

As shown in FIG. 1, a pillar garnish 1 is a vehicle interior material that is attached to a center pillar made of sheet metal from the inside of a vehicle using an attachment member such as a clip. The pillar garnish 1 includes a plate-shaped main wall 1A, a plate-shaped front wall 1B that curves toward the outside of the vehicle from the front end of the main wall 1A, and a front wall 1B that curves toward the exterior of the vehicle from the rear end of the main wall 1A. It is a curved plate-shaped body having a plate-shaped rear wall part 1C and having its longitudinal direction in the vertical direction as a whole. The pillar garnish 1 includes a plate-shaped base material 10 (the part shown in white) made of fibers and a thermoplastic resin, and a resin molded part 30 (the shaded part) made of the thermoplastic resin and bonded to the base material 10. (the part shown). A rectangular opening 15 is provided in the center of the base material 10 in the direction of the interior and exterior of the vehicle interior.

As the fibers constituting the base material 10, fibers derived from trunks, stems, branches, leaves, roots, etc. of plants may be used as they are, and these may be subjected to heat treatment, drying treatment, pulverization treatment, chemical treatment, etc. Fibers processed by may also be used. Such vegetable fibers include kenaf, jute hemp, manila hemp, sisal hemp, flax, ramie, hemp, gampi, mitsumata, camellia, banana, pineapple, coconut palm, corn, sugar cane, bagasse, palm (oil palm, etc.), and papyrus. , reed, esparto, sabai grass, tossa, wheat, rice, bamboo, coniferous trees (cedar, cypress, etc.), hardwood, kapok, cotton, etc. can be employed. Among these, the Malvaceae family, which has woody stems, is an extremely fast-growing annual plant, has excellent carbon dioxide absorption, and contributes to reducing the amount of carbon dioxide in the atmosphere and making effective use of forest resources. Linear fibers (kenaf fibers) derived from the plant kenaf are particularly preferred. Examples of this kenaf include scientific names such as Hibiscus cannabinus and Hibiscus sabdariffa, and common names such as red hemp, Cuban kenaf, western hemp, Thai kenaf, mesta, bimli, ambari hemp, and Bombay hemp.

The thermoplastic resins constituting the base material 10 and the resin molded part 30 include polyolefin resins (polypropylene, polyethylene, etc.), polyester resins (aliphatic polyester resins such as polylactic acid and polycaprolactone, aromatic polyesters such as polyethylene terephthalate, etc.). Resin such as resin) can be adopted. Among these, polypropylene resin is preferred. The thermoplastic resin constituting the base material 10 and the thermoplastic resin constituting the resin molded part 30 may be the same type of thermoplastic resin or may be different types of thermoplastic resins.

As shown in FIGS. 1 and 2, the resin molded part 30 surrounds the entire circumference of the outer end 11 of the base material 10, and its surface (inside surface of the vehicle interior) 30A is flush with the surface 10A of the base material 10. The main body part 31 is joined to the end part 11 of the base material 10 in the form of one body. Further, the resin molded part 30 is connected to the main body part 31 and extends from the main body part 31 toward the inner side (the opening 15 side) of the base material 10 (in the direction away from the main body part 31), and extends from the back surface of the base material 10 (in the direction away from the A plurality of long plate-shaped ribs (extension portions) 32 are provided to extend toward the outdoor side surface 10B. The plurality of ribs 32 extend from the back surface of the side walls 1B, 1C of the pillar garnish 1 to the back surface of the end in the front-rear direction of the main wall 1A, and extend perpendicularly to the back surface 10B of the base material 10. By standing upright, the base material 10 and the main body part 31 of the resin molded part 30 are reinforced.

As shown in FIG. 2, the plurality of ribs 32 described above and the clip seat 40 disposed above the opening 15 are provided on the back surface 10B side of the base material 10. The clip seat 40 is made of the same type of thermoplastic resin as the resin molded part 30, and is erected from the back surface 10B of the base material 10 toward the outside of the vehicle interior. By attaching an attachment member such as a clip to the clip seat 40, the pillar garnish 1 can be attached to the center pillar from inside the vehicle interior. The clip seat 40 includes a pedestal part 41 that forms the majority, and a plurality of reinforcing parts 42 that extend in a direction away from the pedestal part 41 and that reinforce the pedestal part 41.

FIG. 3 is an enlarged view of the periphery of one of the plurality of ribs 32 in the resin molded part 30 (the rib 32D disposed at the lower front in FIG. 2). The rib 32 has a proximal end portion 33 located on the main body 31 side (on the outer end 11 side of the base material 10) and a proximal end portion 33 located on the inner side of the base material 10 (on the opening 15 side) than the proximal end portion 33. The distal end portion 34 is a portion located in the direction (direction away from the main body portion 31), and the overall shape is tapered from the proximal end portion 33 toward the distal end portion 34.

The base material 10 includes a high-density portion 16 as a portion located around where the proximal end portion 33 is joined, and a low-density portion 17 as a portion located around where the distal end portion 34 is joined. Further, a portion located between the high-density portion 16 and the low-density portion 17 is a gradually changing portion 18 . As shown in FIGS. 4 and 5, the low-density portion 17 is thicker than the high-density portion 16 and has a lower density. It can also be said that the low-density portion 17 is a portion that is raised toward the back side of the portion located around the low-density portion 17 . The gradually changing portion 18 is a portion where the plate thickness gradually increases and the density gradually decreases from the high density portion 16 toward the low density portion 17. A portion 19 located further inside (toward the opening 15 side) than the low-density portion 17 has a thinner plate thickness and higher density than the low-density portion 17, similar to the high-density portion 16.

Next, the mold 2 as a manufacturing device for manufacturing the pillar garnish 1 will be explained. As shown in FIG. 6, the mold 2 presses a fiber resin body 9 made of fibers and a thermoplastic resin from above and below (inside and outside of the vehicle interior in the pillar garnish 1) to form a base material 10. It is said that The mold 2 is arranged above and has an upper mold 50 having a molding surface 50A that presses the fiber resin body 9 from the back surface 10B of the base material 10, and is arranged below so as to face the upper mold 50. , a lower die 60 having a molding surface 60A for pressing the fiber resin body 9 from the side of the base material 10 that becomes the surface 10A. Note that the fibers and thermoplastic resin that make up the fiber resin body 9 are the same as the fibers and thermoplastic resin that make up the base material 10 of the pillar garnish 1 described above.

The upper mold 50 is a movable mold that can be moved vertically relative to the lower mold 60 by a drive device (for example, an electric motor, an air cylinder, a hydraulic cylinder, etc.) not shown. FIG. 6 shows a state in which the upper mold 50 moves away from the lower mold 60 and the mold 2 is opened. FIG. 7 shows a state in which the upper mold 50 moves toward the lower mold 60 and the mold 2 is closed. When the mold 2 is closed, a space (molding space) S is formed between the recesses 51, 52, 53 (described later) of the upper mold 50 and the pressed fiber resin body 9 (base material 10). . In addition, in FIGS. 7 and 10, it is assumed that the molding space S extends in the area between the dotted line and the base material 10, which is on the back side of the page.

An injection device 70 capable of injecting molten thermoplastic resin and a hole-shaped sprue 72 for flowing the thermoplastic resin injected from the injection device 70 into the molding space S are provided above the upper mold 50. ing. The injection device 70 can inject the molten thermoplastic resin into the molding space S via the sprue 72. The thermoplastic resin injected from the injection device 70 is the same as the thermoplastic resin forming the resin molded portion 30 of the pillar garnish 1 described above.

The upper mold 50 includes concave recesses 51, 52, and 53 provided on the molding surface 50A side. The recesses 51 , 52 , and 53 are connected to the sprue 72 and are connected to the main body recess 51 , which is a part where the thermoplastic resin constituting the main body 31 of the resin molded part 30 flows. The thermoplastic resin forming the proximal end 33 of the rib 32 (see FIG. 4) flows into the inflow recess 52 and is connected to the inflow recess 52 and flows into the inflow recess 52. A terminal recess 53 is provided, which is a terminal portion in the flow direction of the thermoplastic resin and is a portion where the thermoplastic resin constituting the tip portion 34 of the rib 32 flows and is filled. The inflow recess 52 extends in the vertical direction, whereas the terminal recess 53 extends from the lower end of the inflow recess 52 in a gradual curve in the left-right direction (vehicle longitudinal direction in the pillar garnish 1). There is. As shown in FIG. 7, when the mold 2 is closed, a molding space S is formed between the recesses 51, 52, 53 of the upper mold 50 and the pressed fiber resin body 9 (base material 10). has a shape that tapers from the main body recess 51 side toward the terminal recess 53 side.

As shown in FIGS. 6 and 7, around the inflow recess 52, there is a high-density molding surface 52A that presses the fiber resin body 9 from the back side of the high-density portion 16 (see FIG. 4) of the base material 10. is located. Furthermore, a low-density molding surface 53A is located around the terminal recess 53 to press the fiber resin body 9 from the back side of the low-density portion 17 of the base material 10. Further, between the high-density molding surface 52A and the low-density molding surface 53A, there is a gradually changing molding surface 54A that presses the fiber resin body 9 from the back side of the gradually changing portion 18 of the base material 10. . As shown in FIG. 9, when the mold 2 is closed, the distance L1 between the molding surface 60A of the lower mold 60 and the low-density molding surface 53A is as shown in FIG. It is longer than the distance L2 between 60A and the high-density molding surface 52A. Further, as shown in FIG. 7, the distance between the molding surface 60A of the lower die 60 and the gradually changing molding surface 54A gradually increases from the high-density molding surface 52A toward the low-density molding surface 53A.

Next, a method for manufacturing the pillar garnish 1 will be explained. The manufacturing method of the pillar garnish 1 can be roughly divided into a pressing step in which a fiber resin body 9 is pressed by a mold 2 to produce a plate-shaped base material 10, and a pressing step in which a plate-shaped base material 10 is produced by pressing a fiber resin body 9 with a mold 2; Injection to produce the resin molded part 30 bonded to the base material 10 by injecting thermoplastic resin into the molding space S formed between the recesses 51, 52, 53 of the mold 50 and the pressed base material 10 process.

As shown in FIGS. 6 and 7, in the pressing step, the open mold 2 is heated, and the fiber resin body 9 is placed between the upper mold 50 and the lower mold 60. Then, by bringing the upper mold 50 close to the lower mold 60 and pressing the fiber resin body 9 from above and below with the mold 2 closed, a base material 10 that is thinner than the fiber resin body 9 is molded. . The fiber resin body 9 is shaped so that the surface 9A, which is the surface 10A (see FIG. 1) of the base material 10, is pressed against the molding surface 60A of the lower mold 60, so that it follows the shape of the molding surface 60A. molded. Furthermore, the back surface 9B of the base material 10, which is the back surface 10B (see FIG. 2), is pressed against the molding surface 50A of the upper die 50, so that the fiber resin body 9 follows the shape of the molding surface 50A. It is formed like this.

As shown in FIGS. 6, 7, and 8, the end portion 9C of the fiber resin body 9 pressed by the molding surface 60A of the lower mold 60 and the high-density molding surface 52A of the upper mold 50 It is molded as a high-density portion 16. Further, as shown in FIGS. 6 to 9, a portion 9D of the fiber resin body 9 pressed by the molding surface 60A of the lower mold 60 and the low-density molding surface 53A of the upper mold 50 is removed when the mold 2 is closed. In this state, the distance L1 between the molding surface 60A of the lower mold 60 and the low-density molding surface 53A is longer than the distance L2 between the molding surface 60A of the lower mold 60 and the high-density molding surface 52A. The material 10 is formed as a low-density portion 17 that is thicker and lower in density than the high-density portion 16 . Further, a portion 9E of the fiber resin body 9 pressed by the molding surface 60A of the lower mold 60 and the gradually changing molding surface 54A of the upper mold 50 is removed from the molding surface of the lower mold 60 when the mold 2 is closed. Since the distance between 60A and the gradually changing molding surface 54A gradually increases from the high-density molding surface 52A toward the low-density molding surface 53A, the distance between the high-density molding surface 52A and the gradually changing molding surface 54A gradually increases from the high-density portion 16 to the low-density portion 17 in the base material 10. It is formed as a gradually changing portion 18 in which the plate thickness gradually increases and the density gradually decreases toward the end.

Next, in the injection process, as shown in FIG. 10, while pressing the fiber resin body 9 (base material 10) with the mold 2 heated to a predetermined temperature, the molten thermoplastic resin is injected from the injection device 70 into the molding space S. (concavities 51, 52, 53). The thermoplastic resin (indicated by a plurality of dots in the molding space S) injected from the injection device 70 flows through the main body recess 51 via the sprue 72 and then flows into the inflow recess 52 . The thermoplastic resin that has flowed downward (inward the vehicle interior) through the inflow recess 52 changes its flow direction to the left (towards the rear of the vehicle) along the gradual change section 18 and fills the terminal recess 53 . The thermoplastic resin filling the molding space S mixes with the thermoplastic resin constituting the base material 10. After maintaining this state for a predetermined period of time, by cooling the mold 2, the thermoplastic resin that has flowed into the main body recess 51 is transferred to the main body 31 joined to the end 11 of the base material 10, as shown in FIG. Become. Further, the thermoplastic resin that has flowed into the inflow recess 52 becomes the proximal end 33 joined to the high-density part 16 of the base material 10, and the thermoplastic resin that has flowed to the terminal recess 53 becomes the low-density part 17 of the base material 10. This becomes the joined tip portion 34. In this way, the pillar garnish 1 in which the ribs 32 are joined to the base material 10 is manufactured.

Next, the effects of this embodiment will be explained. In this embodiment, a method for manufacturing a pillar garnish 1 is described, in which a fibrous resin body 9 made of fibers and a thermoplastic resin is pressed by molding surfaces 50A and 60A of a mold 2 to form a plate-shaped base material 10. Pressing process to produce and injecting thermoplastic resin into the concave recesses 52 and 53 provided in the upper mold 50 of the mold 2 while pressing the base material 10 with the molding surfaces 50A and 60A of the mold 2 The recesses 52 and 53 include an inflow recess 52 into which the injected thermoplastic resin flows, and an injection step in which the resin molded part 30 is bonded to the base material 10. In the pressing step, the substrate 10 is pressed by a low-density molding surface 53A, which is a molding surface located around the terminal recess 53. The density of the low-density portion 17 as a portion that is pressed is lower than the density of the high-density portion 16 as a portion that is pressed by the high-density molding surface 52A that is a molding surface located around the inflow recess 52. A method for manufacturing the pillar garnish 1 by pressing the resin body 9 was shown.

According to such a manufacturing method of the pillar garnish 1, in the pressing step, the density of the low-density portion 17 of the base material 10 pressed by the low-density molding surface 53A of the mold 2 is reduced by the high-density molding surface 52A. Since the density is set to be lower than that of the pressed high-density portion 16, various gases may pass through the low-density portion 17 when thermoplastic resin is injected into the recesses 52 and 53 in the injection process. The thermoplastic resin can be filled up to the terminal recess 53. Then, it is possible to obtain a highly rigid pillar garnish 1 in which the resin molded portion 30 of a desired shape is joined to the base material 10.

In addition, in the pressing process, in the base material 10, the plate thickness of the low-density portion 17 as a portion pressed by the low-density molding surface 53A, which is a molding surface located around the end recess 53, is increased to the periphery of the inflow recess 52. The fiber resin body 9 is pressed so that it becomes thicker than the plate thickness of the high-density portion 16 as the portion pressed by the high-density molding surface 52A, which is the molding surface located thereon. According to such a manufacturing method of the pillar garnish 1, a highly rigid pillar garnish 1 in which a resin molded part 30 of a desired shape is bonded to a base material 10 having a low density part 17 and a high density part 16 can be easily manufactured. be able to.

In addition, in the pressing process, in the base material 10, the molding located around the terminal recess 53 from the high-density portion 16 side as a portion pressed by the high-density molding surface 52A, which is the molding surface located around the inflow recess 52. The fiber resin body 9 is pressed under conditions such that the density gradually decreases toward the low-density portion 17, which is the portion pressed by the low-density molded surface 53A. According to such a manufacturing method of the pillar garnish 1, when thermoplastic resin is injected into the recesses 52 and 53 in the injection process, various gases can gradually pass through toward the end recess 53, The thermoplastic resin can suitably fill up to the terminal recess 53.

Further, in the pressing step, the end portion 9C of the fiber resin body 9 is pressed by the high-density molding surface 52A as a molding surface located around the inflow recess 52. According to such a method of manufacturing pillar garnish 1, it is possible to manufacture highly rigid pillar garnish 1 in which end portion 11 of base material 10 is reinforced by resin molded portion 30.

Further, in the present embodiment, the pillar garnish 1 includes a plate-shaped base material 10 made of fibers and a thermoplastic resin, and a resin molded part 30 made of a thermoplastic resin and bonded to the base material 10. The resin molded part 30 includes a main body part 31 and a rib 32 connected to the main body part 31 and extending in a direction away from the main body part 31, and the rib 32 is provided on the main body part 31 side. The base material 10 includes a base end portion 33 disposed in the base end portion 33 and a distal end portion 34 disposed in a direction farther from the main body portion 31 than the base end portion 33 . , the pillar garnish 1 is shown including a low-density portion 17 having a lower density than the high-density portion 16 and to which the tip portion 34 is joined. According to such a pillar garnish 1, it is possible to provide a highly rigid pillar garnish 1 in which the resin molded part 30 is joined from the high-density part 16 to the low-density part 17 in the base material 10.

Further, the main body portion 31 is arranged at the end portion 11 of the base material 10. According to such a pillar garnish 1, it is possible to provide a highly rigid pillar garnish 1 in which the end portion 11 of the base material 10 is reinforced by the resin molded portion 30.

<Other embodiments>
The present invention is not limited to the embodiments described above and illustrated in the drawings; for example, the following embodiments are also included within the technical scope of the present invention; It can be implemented with various modifications.

(1) In addition to the embodiments described above, the configuration of the mold can be modified as appropriate. For example, when manufacturing a molded structure having an undercut shape, the mold may include a slide mold for molding the undercut shape.

(2) The method for manufacturing a molded structure shown in the above embodiment may include a packing step of packing the high-density portion. Specifically, the molding surface (high-density molding surface) located around the inflow recess is shaped to form a convex shape in the direction of the lower mold, and during the pressing process, the thickness of the high-density part is made thinner than other parts. It is also possible to press the fiber resin body so as to pack it into a board.

(3) In the above embodiment, the resin molded portion is bonded to the outer end of the base material, but the present invention is not limited to this. For example, the resin molded portion may be an inner end of the base material and may be joined to an end of the opening. Further, the resin molded portion may be a clip seat. In that case, the main body part is made into a pedestal part, and the extension part is made into a reinforcing part.

(4) In addition to the embodiments described above, the molded structure can be modified as appropriate. In the above embodiment, the molded structure is a pillar garnish, but it is not limited to this. For example, the molded structure may be a door trim, an instrument panel, a cowl side trim, or other vehicle interior trim.

(5) The method for manufacturing a molded structure and the molded structure exemplified in the above embodiments are not limited to those provided as interior materials for vehicles, but may be provided as interior materials for various vehicles. good. For example, the method for manufacturing the molded structure described above can also be applied to interior materials for vehicles such as trains and recreational vehicles as ground vehicles, airplanes and helicopters as flying vehicles, and ships and submarines as vehicles on the sea and under the sea. Molded structures can be applied.

DESCRIPTION OF SYMBOLS 1... Pillar garnish (molding structure), 2... Molding mold, 9... Fiber resin body, 10... Base material, 16... High density part, 17... Low density part, 18... Gradual change part, 30... Resin molding part, 31... Main body part, 32... Rib (extending part), 33... Base end part, 34... Tip part, 52... Inflow recessed part (recessed part), 52A... High-density molded surface (molded surface located around the inflow recessed part) , 53... End recess (recess), 53A... Low density molding surface (molding surface located around the end recess)

Claims (5)

a pressing step of producing a plate-shaped base material by pressing a fiber resin body composed of at least fibers and a thermoplastic resin with a molding surface of a mold;
Injection to produce a resin molded part bonded to the base material by injecting at least a thermoplastic resin into a concave recess provided in the mold while pressing the base material with a molding surface of the mold. The process includes;
The recess includes an inflow recess into which the injected thermoplastic resin flows, and an end recess which is an end portion in the flow direction of the thermoplastic resin flowing from the inflow recess side,
In the pressing step, the density of the portion of the base material pressed by the molding surface located around the terminal recess is lower than the density of the portion pressed by the molding surface located around the inflow recess. The condition is such that the thickness of the portion pressed by the molding surface located around the end recess is thicker than the thickness of the portion pressed by the molding surface located around the inflow recess. A method for producing a molded structure, characterized by pressing a fiber resin body. In the pressing step, in the base material, the density gradually increases from the side of the part pressed by the molding surface located around the inflow recess to the side of the part pressed by the molding surface located around the end recess. The method for manufacturing a molded structure according to claim 1, characterized in that the fiber resin body is pressed under conditions that reduce the pressure. 3. The method for manufacturing a molded structure according to claim 1 , wherein in the pressing step, an end portion of the fiber resin body is pressed by a molding surface located around the inflow recess. A plate-shaped base material composed of at least fibers and thermoplastic resin;
a resin molded part made of at least a thermoplastic resin and joined to the base material,
The resin molded part includes a main body part and an extension part connected to the main body part and extending in a direction away from the main body part,
The extension part is
a base end portion disposed on the main body side;
a distal end disposed in a direction farther from the main body than the proximal end;
The base material is
a high-density portion where the base end portion is joined;
A molded structure comprising: a low-density portion to which the tip portion is joined and has a lower density than the high-density portion. 5. The molded structure according to claim 4 , wherein the main body is disposed at an end of the base material.

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